Vacuum Coating of Plastic Door Frames

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Solution Overview

Problem

Plastic door and window frames lack durability and aesthetic appeal, leading to frequent maintenance needs and increased costs, as existing coating methods are not long-lasting and easily damaged by human actions or atmospheric agents.

Innovation Solution

A vacuum-based physical vapor deposition process using a pulsed dc magnetron for cathode sputtering, combining inert and reactive gases to deposit a durable coloring layer and a transparent protective layer on plastic profiled elements, enhancing their resistance and aesthetic appearance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If conventional coloring layers are applied to plastic frames, then aesthetic appearance is improved, but durability and resistance to damage are worsened

Engineering Contradiction:

Improveaesthetic appearanceVSAvoiddurability

Core Design Contradiction:

Illumination intensityVSReliability

Solution Approach 1:

The patent applies a composite coating structure consisting of multiple layers: a coloring layer for aesthetic appearance and a protective layer for durability and resistance to damage. This composite structure resolves the contradiction by combining materials with different functions - the coloring layer provides visual appeal while the protective layer ensures long-term durability and resistance to human actions and atmospheric agents.

Inventive Principle:

Principle #40Composite materials

2Illumination intensity

If conventional coating methods are used, then aesthetic appearance is improved, but maintenance requirements increase

Engineering Contradiction:

Improveaesthetic appearanceVSAvoidmaintenance operations

Core Design Contradiction:

Illumination intensityVSEase of operation

Solution Approach 1:

The protective layer in the composite coating structure is specifically designed to resist atmospheric agents and human actions, thereby reducing the frequency and complexity of maintenance operations. This layer acts as a barrier that protects the underlying coloring layer from degradation, eliminating the need for frequent restoration of aesthetic appearance.

Inventive Principle:

Principle #40Composite materials

3Reliability

If vacuum-based physical vapor deposition is used, then coating durability is improved, but device complexity increases

Engineering Contradiction:

Improvecoating durabilityVSAvoidvacuum machinery complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces conventional mechanical coating methods with vacuum-based physical vapor deposition technology. This substitution uses physical processes (vapor deposition in vacuum) instead of mechanical application methods, resulting in more durable coatings that are molecularly bonded to the substrate. The vacuum environment enables precise control of the deposition process and ensures uniform, adherent coating layers.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Reliability

If multiple coating layers are deposited, then protective properties are improved, but manufacturing time increases

Engineering Contradiction:

Improveprotective propertiesVSAvoidmanufacturing time

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent combines multiple coating operations into a single integrated vacuum deposition process. By maintaining the vacuum environment throughout the process, the coloring layer and protective layer can be deposited sequentially without breaking vacuum, eliminating the need for intermediate handling and atmospheric exposure. This merging of operations reduces total manufacturing time while ensuring proper adhesion between layers.

Inventive Principle:

Principle #5Merging (Combining)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The process results in long-lasting, low-maintenance plastic frames with improved aesthetic appeal, resistant to human actions and atmospheric agents, reducing maintenance costs and enhancing customer attractiveness.

Implementation Method 1

a device for physical vapor deposition 3 adapted to the coating of at least one profiled element 4

Methodology Applied

Scientific EffectPhysical vapor deposition: Physical Vapour Deposition

Implementation Method 2

using a pulsed dc magnetron for cathode sputtering

Methodology Applied

Scientific EffectCathode sputtering: Sputtering

Data Source

PatentEP3405594B1Procedure for the coating of profiled elements made of plastic material for door and window frames

Publication Date: 2021.04.14 GRAF SYNERGY

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Figure 2~4
Figure 5~6

AI summary

The procedure for the coating of profiled elements made of plastic material for door and window frames comprises: - a step of supply of a vacuum machinery (1) comprising a vacuum cabin (2) having at least a device for physical vapor deposition (3) suitable for the coating of at least one profiled element (4) made of plastic material to be coated for the manufacture of door and window frames; - a step of insertion of the profiled element (4) within the vacuum cabin (2); - a first step of introduction of a coloring material (CI) within the vacuum cabin (2); - a first step of physical vapor deposition for the coating of the profiled element (4) with the coloring material (CI) to obtain a coloring layer (15), the coloring layer (15) covering at least partly the surface of the profiled element (4); - a second step of introduction of an at least partly transparent protective material (PI) within the vacuum cabin (2); - a second step of physical vapor deposition for the coating of the profiled element (4) with the protective material (PI) to obtain a protective layer (16) suitable for covering at least partly the coloring layer (15).